Thermal Spray Coating Apparatus and Method of Use

ABSTRACT

This invention discloses a metal coating method whereby an abrasion resistant and wear resistant coating is first applied to the that portion of a metal object of extended size to be protected, the coating is then fused onto the metal object with the use of a temperature controlled induction heater, which results in a metal object, at least a portion of which is more abrasion resistant and wear resistant than the uncoated metal object.

CROSS-REFERENCE TO RELATED APPLICATIONS

61/818,276 May, 2013 Hill

Ser, No, 14/173,009 February, 2014 Hill

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC

Not Applicable

DESCRIPTION Field of the Invention

This invention discloses a thermal spray coating apparatus for the adhering of a coating that is abrasion resistant and wear resistant to an object as well as a method of applying said coating on that object.

Background of the Invention

Metal objects such as augers are used in the agricultural, construction and material handling industries to breakup soil and other materials and to transport materials from one location to another. Over the operational life of these metal objects, they are exposed to abrasive conditions that cause the metal objects to wear out. Attempts have been made to extend the life of said metal objects by affixing abrasive resistant and wear resistant coatings onto them, which would then increase the life of the metal object, decrease maintenance downtime and decrease replacement costs. However, pasted on abrasive resistant and wear resistant coatings scrape off during use of the metal objects. The present disclosure teaches a thermal spray coating apparatus for adhering the coating onto the metal object and a method of adhering the coating to the metal object.

SUMMARY OF THE INVENTION

The present disclosure reveals a thermal spray coating apparatus for adhering a coating that is abrasion resistant and wear resistant onto a metal object comprising a pair of torches, a plurality of mechanical guides to guide torches along the metal object and stop the process in accordance with the positioning of the relative to the metal object, and a means of moving the metal object past the torches, the torches past the metal object, or a means for moving the metal object while the torches move over the metal object. The first torch sprays the coating onto the metal object and adheres the coating and metal object while the second torch further heats the coating and metal object to complete the adhering process. The plurality of guides are used to position the torches relative to the metal object and to indicate when the process is complete.

The first embodiment of the thermal spray coating apparatus for adhering a coating onto a metal object reveals a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives, wherein the plurality of drives facilitate the movement of the pair of torches past the metal object.

The second embodiment of the thermal spray coating apparatus for adhering a coating onto a metal object reveals a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives wherein the plurality of drives facilitate the movement of the metal object past the pair of torches.

The third embodiment of the thermal spray coating apparatus for adhering a coating onto a metal object reveals a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives wherein the plurality of drives facilitate the movement of the pair of torches past the metal object while the plurality of drives facilitate the movement of the metal object.

A method of applying a coating that is abrasive resistant and wear resistant to a metal object that will be exposed to abrasive materials, where the metal object is first cleaned to remove rust, dirt and other foreign material from the surface of the metal object, installing the metal object in an apparatus for applying a coating onto the metal object, applying the coating with the use of a first torch, and then fusing the abrasive resistant and wear coating to the metal object with the use of a second torch.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a display of the first embodiment of the thermal spray coating apparatus for adhering a coating onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives, wherein the plurality of drives facilitate the movement of the pair of torches past the metal object;

FIG. 2 is a display of the second embodiment of the thermal spray coating apparatus for adhering a coating onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives wherein the plurality of drives facilitate the movement of the metal object past the pair of torches;

FIG. 3 is a display of the third embodiment of the thermal spray coating apparatus for adhering a coating onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives wherein the plurality of drives facilitate the movement of the pair of torches past the metal object while the plurality of drives facilitate the movement of the metal object; and

FIG. 4 is a display of the method for adhering a coating onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure reveals a thermal spray coating apparatus 1 for adhering a coating 2 that is abrasion resistant and wear resistant onto a metal object 3 comprising a torch system 4, a rack system 5, a coating feed system 6, a plurality of guides 7, and a plurality of drives 8.

The torch system 4 comprises a pair of torches 9, that being a first torch 10 and a second torch 11, a plurality of gas cylinders 12 containing gas to facilitate the heating process, connections 13 to connect the plurality of gas cylinders 12 to the pair of torches 9, a control mechanism 14 to activate and deactivate the flow of the gases to the pair of torches 9, an attachment 15 to connect the first torch 10 to the coating feed system 6, and a plurality of guides 7. The pair of torches 9 create a stream of energy to heat a compound 16 that creates the coating 2 on the metal object 3, as well as the metal object 3, and by heating the compound 16 and metal object 3, also cause the adhesion of the compound 16 to the metal object 3. The pair of torches 9 may be of an oxy-acetylene or plasma type. The plurality of guides 7 aid in properly positioning the pair of torches 9 relative to the metal object 3 and in the deactivation of the apparatus 1. The plurality of guides 7 may be made up of mechanical guides, optical guides such as a laser sensor, or a combination of mechanical guides and optical guides.

The rack system 5 is designed to have the metal object 3 attached to it and comprises a frame 17, a structure 18 to hold the pair of torches 9 and allow the proper positioning of the pair of torches 9 during the coating of the metal object 3, a plurality of attachments 19 that hold the metal object 3 and allow the metal object 3 to be manipulated while the compound 16 is being applied, and the plurality of drives 8 wherein the plurality of drives 8 could comprise devices such as motors, levers and pullies, or mechanical cranks to facilitate movement and that could be connected to the structure 18 that holds the pair of torches 9 or connected to the plurality of attachments 19, and facilitate the manipulation of the metal object 3 or the manipulation of the structure 18 that holds the pair of torches 9.

The coating feed system 6 comprises a coating storage container 20, which holds the compound 16 to that becomes the coating 2 on the metal object 3, and the attachment 15 from the coating storage container 20 to the first torch 10 such that, when the apparatus 1 is activated, the compound 16 flows from the coating storage container 20 to the first torch 10, so that the compound 16 can enter the flow of the gas from the plurality of gas cylinders 12, whereupon, the compound 16 is applied onto the metal object 3 as the first torch 10 also heats the metal object 3.

In the first embodiment 21, the plurality of drives 8 facilitate the movement of the pair of torches 9 past the metal object 3. In the second embodiment 22, the plurality of drives 8 facilitate the movement of the metal object 3 past the pair of torches 9. In the third embodiment 23, the plurality of drives 8 facilitate the movement of the metal object 3 and facilitate the movement of the pair of torches 9.

The present disclosure reveals a method of operation of an apparatus 1 for adhering a coating 2 that is abrasion resistant and wear resistant onto a metal object 3, wherein the apparatus 1 comprises a torch system 4, a rack system 5, a coating feed system 6, a plurality of guides 7, and a plurality of drives 8, the method of operation comprising first 25, cleaning the metal object 3, to remove rust, dirt and other foreign material from the surface of the metal object 3, said cleaning to occur with the use of an abrasive such as sand blasting or other appropriate method common in the art for the removal of rust. Second, the metal object 3 is attached to the rack system 5 by a plurality of attachments 19. Third, a pair of torches 9 of the torch system 4, that being a first torch 10 and a second torch 11, are positioned relative to the metal object 3. Fourth, the plurality of guides 7 are positioned. Fifth, the apparatus 1 is activated to begin the operation of coating the metal object 3. During operation the plurality of drives 8 facilitate the movement for the metal object 3 to be coated. Also during operation, the first torch sprays 10 a compound 16 derived from the coating feed system 6 onto the metal object 3 and heats the compound 16 and metal object 3 to begin the process of adhering the compound 16 onto the metal object 3. The second torch 11, which follows behind the first torch 10, continues to heat the compound 16 and the metal object 3 to complete the adhering process. The heating of the compound 16 and metal object 3 by the first torch 10 allows the second torch 11 to not need to heat the compound 16 and metal object 3 as much in order to assure the adhesion of the compound 16 onto the metal object 3. Sixth, once the plurality of guides 7 reach a designated position relative to the metal object 3 the apparatus 1 is deactivated. During the operation of the apparatus 1, the metal object 3 may be moved past the pair of torches 9, the pair of torches 9 may be moved past the metal object 3, or the metal object 3 may be manipulated while the pair of torches 9 also progresses. 

What is claimed:
 1. A thermal spray coating apparatus for adhering a coating that is abrasion resistant and wear resistant onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives; the torch system comprises a pair of torches, that being a first torch and a second torch, a plurality of gas cylinders, a plurality of connections to connect the plurality of gas cylinders to the pair of torches, a control mechanism to activate and deactivate the flow of the gases to the torches and to activate the thermal spray coating apparatus, an attachment to connect the first torch to the coating feed system, and a plurality of guides; the rack system comprises a frame, a structure to hold the pair of torches and allow the proper positioning of the torches while a compound is applied to the metal object, a plurality of attachments that hold and allow the metal object to be manipulated during the coating process, and a plurality of drives that are attached to the structure that hold the pair of torches and facilitate the manipulation of the pair of torches past the metal object; and the coating feed system comprises a coating storage container, and the attachment from the coating storage container to the first torch such that, when the torches are activated the compound flows from the coating storage container, through the attachment, to the first torch, enters the flow of the gas from the plurality of gas cylinders, whereupon, the compound is applied onto the metal object as the first torch also heats the metal object.
 2. A thermal spray coating apparatus for adhering a coating that is abrasion resistant and wear resistant onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives; the torch system comprises a pair of torches, that being a first torch and a second torch, a plurality of gas cylinders, a plurality of connections to connect the plurality of gas cylinders to the pair of torches, a control mechanism to activate and deactivate the flow of the gases to the torches and to activate the thermal spray coating apparatus, an attachment to connect the first torch to the coating feed system, and a plurality of guides; the rack system comprises a frame, a structure to hold the pair of torches and allow the proper positioning of the torches while the compound is applied to the metal object, a plurality of attachments that hold and allow the metal object to be manipulated during the coating process, and a plurality of drives that are attached to the plurality of attachments and facilitate the manipulation of the metal object past the pair of torches; and the coating feed system comprises a coating storage container, and an atttachment from the coating storage container to the first torch such that, when the torches are activated the compound flows from the coating storage container through the attachment to the first torch, enters the flow of the gas from the plurality of gas cylinders, whereupon, the compound is applied onto the metal object as the first torch also heats the metal object.
 3. A thermal spray coating apparatus for adhering a coating that is abrasion resistant and wear resistant onto a metal object comprising a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives; the torch system comprises a pair of torches, that being a first torch and a second torch, a plurality of gas cylinders, a plurality of connections to connect the plurality of gas cylinders to the pair of torches, a control mechanism to activate and deactivate the flow of the gases to the torches and to activate the thermal spray coating apparatus, attachments to connect the first torch to the coating feed system, and a plurality of guides; the rack system comprises a frame, a structure to hold the pair of torches and allow the proper positioning of the torches during the coating of the metal object, a plurality of attachments that hold and allow the metal object to be manipulated during the coating process, and a plurality of drives that are attached to the structure that hold the pair of torches, attached to the plurality of attachments, and facilitate the manipulation of the metal object and the manipulation of the structure that holds the pair of torches during the application of the compound to the metal object; and the coating feed system comprises a coating storage container, and an attachment from the coating storage container to the first torch such that, when the torches are activated the compound flows from the coating storage container, through the attachment, to the first torch, enters the flow of the gas from the plurality of gas cylinders, whereupon, the compound is applied onto the metal object as the first torch also heats the metal object.
 4. A method of operation of a thermal spray coating apparatus for adhering a coating that is abrasion resistant and wear resistant onto a metal object, wherein the thermal spray coating apparatus comprises a torch system, a rack system, a coating feed system, a plurality of guides, and a plurality of drives, the method of operation comprising: first, cleaning the metal object, to remove rust, dirt and other foreign material from the surface of the metal object; second, the metal object is attached to the rack system with the use of a plurality of attachments; third, a pair of torches of the torch system, that being a first torch and a second torch, are positioned relative to the metal object; fourth, the plurality of guides are positioned; fifth, the thermal spray coating apparatus is activated to begin the operation of coating the metal object; during operation the plurality of drives facilitate the movement for the metal object to be coated; also during operation, the first torch sprays a compound derived from the coating feed system onto the metal object and heats the compound and metal object to begin the process of adhering the compound onto the metal object and the second torch, which follows behind the first torch, continues to heat the compound and the metal object to complete the adhering process; and sixth, once the plurality of guides reach a designated position relative to the metal object the thermal spray coating apparatus is deactivated.
 5. The method of operation of the thermal spray coating apparatus of claim 4 wherein, during the operation of the thermal spray coating apparatus, the metal object is moved past the pair of torches.
 6. The method of operation of the thermal spray coating apparatus of claim 4 wherein, during the operation of the thermal spray coating apparatus, the pair of torches may be moved past the metal object.
 7. The method of operation of the thermal spray coating apparatus of claim 4 wherein, during the operation of the thermal spray coating apparatus, the metal object may be manipulated while the pair of torches also progresses. 